A Battery Management System Capable of Analyzing Abnormal Cell Trends

The operational safety and longevity of Lithium-ion Nickel Manganese Cobalt Oxide (NMC) battery packs depend on the early detection of gradual cell degradation rather than reactive fault protection. Conventional Battery Management Systems (BMS) predominantly rely on fixed threshold-based mechanisms, which are insufficient for identifying long-term abnormal trends at the individual cell level preceding failure. This studyproposes an intelligent IoT-based battery monitoring and visualization framework for trend-oriented abnormal behavior analysis in a 72 V, 20 cell NMC battery pack. A JK-BMS performs cell voltage acquisition, while an ESP32-S3 microcontroller operates as an IoT gateway, wirelessly collecting high-resolution cell level data via Bluetooth Low Energy (BLE). The data are transmitted to a Home Assistant platform, which provides centralized time-series visualization and comparative cell analytics. The primary contribution is a heuristic anomaly detection algorithm that evaluates temporal voltage trends of individual cells, with emphasis on instability within the critical operating range of 3.0–3.5 V. Unlike conventional threshold-based approaches, the proposed method detects repeated abnormal patterns over time. A frequency-based alert mechanism categorizes battery health into normal, warning, and critical states based on cumulative anomaly occurrences, enabling progressive degradation assessment. Experimental results demonstrate that the proposed framework effectively identifies early-stage degradation patterns that remain undetected by conventional BMS logic. The system supports predictive maintenance, enhances operational safety, and provides a scalable, cost-effective solution for advanced battery health monitoring in electric mobility and distributed energy storage applications.